Design And Testing Of Mechanical Juice Extraction Especially For Sugar Cane.

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‘Saya/Kami* akui bahawa telah membaca karya ini dan pada pandangan saya/kami* karya ini

adalah memadai dari segi skop dan kualiti untuk tujuan penganugerahan Ijazah Sarjana Muda Kejuruteraan Mekanikal (Rekabentuk)’

Tandatangan : ………

Nama Penyelia I : ………

Tarikh : ………

Tandatangan : ………

Nama Penyelia II : ………

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DESIGN AND TESTING OF MECHANICAL JUICE EXTRACTION ESPECIALLY FOR SUGAR CANE

TEH KHANG LING

This report is submitted as partial requirement for the completion of the Bachelor of Mechanical Engineering (Design and Innovation) Degree Program

Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka

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PENGAKUAN

“Saya akui laporan ini adalah hasil kerja saya sendiri kecuali ringkasan dan petikan yang tiap-tiap satunya saya telah jelaskan sumbernya”

Tandatangan : ……….

Nama Penulis : Teh Khang Ling

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DECLARATION

“I hereby, declare this thesis is result of my own research except as cited in the references”

Signature : ……….

Author Name : Teh Khang Ling

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DEDICATION

To

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AKNOWLEDGEMENT

First and foremost, I wish to express my profound gratitude to Mr. Nazim as the final year project supervisor who has gracefully offered his time, attention, experiences and guidance throughout the completion of the investigation thus far.

Besides, would not forget to extend my heartfelt thanks to the university library for providing lots of sources which assistant to complete the report. Besides, would also not forget to thank to the technician who provided help in the sugarcane compression testing.

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ABSTRAK

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ABSTRACT

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LIST OF CONTENTS

CHAPTER TOPIC PAGE

PENGAKUAN ii

DECLARATION iii

DEDICATION iv

AKNOWLEDGEMENT v

ABSTRAK vi

ABSTRACT vii

LIST OF CONTENTS viii

LIST OF TABLES xii

LIST OF FIGRUES xiii

LIST OF SYMBOL xv

LIST OF ABBREVIATIONS xvi

LIST OF APPENDIX xvii

CHAPTER I INTRODUCTION 1

1.1 Background Study 1

1.2 Problem Statement 2

1.3 Objectives 3

1.4 Scope 3

CHAPTER II LITERATURE REVIEW 4

2.1 History and Background of Sugar Cane 4 2.2 Sugar in South Asia 5

2.3 Cultivation of Sugar Cane 6

2.4 Harvesting and Processing 7

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2.6 Gears 9

2.6.1 Spur Gear 11

2.6.2 Spur Gear Forces, Torque,

Velocity & Power 12

2.6.3 Gear Trains 13

2.6.4 Materials Used For Gears 14

2.7 Bearing 16

2.7.1 Bearing Load Life at Rated Reliability 17

2.7.2 Bearing Friction 17

2.8 Shaft 18

2.9 Roller 19

2.9.1 Wear of Sugar Cane Rollers 20 2.10 Computer Aided Engineering (CAE) 20

2.10.1 SolidWorks Premium 2010

Simulation 21

CHAPTER III METHODOLOGY 24

3.1 Methodology and Process Flow of the

Project 24

CHAPTER IV CONCEPTUAL DESIGN 28

4.1 Engineering Design Specification 28 4.2 Explanation on Segment Concept 29

4.3 Morphology Chart 30

4.4 Ten Conceptual Design Generated 33

4.5 Concept Selection Process 43

4.5.1 Concept Scoring 43

4.5.2 Evaluation Chart

(Concept Scoring Matrix) 44 4.5.3 Best Design Concept Selection 47

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CHAPTER TOPIC PAGE

CHAPTER V CONFIGURATION DESIGN 50

5.1 Configuration Design Description 50 5.2 Configuration Design for Selected

Concept 51

CHAPTER VI PARAMETRIC DESIGN 54

6.1 Sugarcane Compression Test 54

6.2 1st_{Calculation on the Design Chosen} ₅₇ 6.3 Calculation on the 1st_Modification ₅₉ 6.4 Calculation on the 2nd_Modification ₆₂

6.4.1 Gear Calculation 62

6.4.2 Calculations on Shafts 66

6.4.3 SolidWorks Analysis on Shafts 71 6.4.4 Optimization on the Shafts 76 6.4.5 Comparison of Theoretical Calculations

And CAE Analysis on Shafts 80 6.4.6 Calculations on Bearings 81

6.5 Part Description 86

CHAPTER VII DETAIL DESIGN 89

7.1 Numbering Part 89

7.2 Product Structure Tree 90

7.2.1 Cluster 1 91

7.2.2 Cluster 2 92

7.2.3 Cluster 3 93

7.2.4 Cluster 4 93

7.2.5 Cluster 5 94

7.2.6 Cluster 6 94

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CHAPTER VIII CONCLUSION AND RECOMMENDATION 99

8.1 Conclusion 99

8.2 Recommendation 100

REFERENCES 101

BIBLIOGRAPHY 104

APPENDIX A 106

APPENDIX B 110

APPENDIX C 113

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LIST OF TABLES

NO. TITLE PAGE

2.1 Material Used For Gears [5] 14

4.1 Concept Scoring Matrix of 10 Conceptual Designs 45

6.1 Comparison of the Original Shafts Diameter and After Optimization 81

6.2 Bearing Table 1 82

7.1 Part Number Characteristics and Descriptions 89 7.2 Engineering Bill of Material of Sugarcane Machine 97 7.3 Product Costing of Sugarcane Machine

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LIST OF FIGURES

2.1 Sugar cane [15] 5

2.2 Harvesting sugar Cane [16] 7

2.3 Sugar cane juice extractor [17] 8

2.4 Mechanism of gear [5] 10

2.5 Profile of a standard 1mm module gear teeth 10

for a gear with Infinite radius [5]

2.6 Spur gear [5] 11

2.7 Number of teeth if spur gear [5] 12

2.8 Symbol definition [5] 12

2.9 Ball bearing [18] 16

2.10 Drive shaft [20] 18

2.11 Rollers [21] 19

2.12 Roller surface before and after wear [11] 20

2.13 The CAD/CAE integrated approach [12] 21

2.14 SolidWorks logo [23] 22

3.1 Flow chart of project methodology 27

4.1 Conceptual design 1 33

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NO. TITLE PAGE

4.11 Best design selected 47

5.1 General classification of knowledge involved in 51 configuration design [14]

5.2 Configuration design 51

6.1 Sugarcane being packed before testing 55

6.2 Destructive test on sugarcane 55

6.3 Sugarcane after compression 55

6.4 Graph plotted for the result of compression of sugarcane 56

6.5 Orientation of gears of 1st_design ₅₇

6.6 CAD Isometric view of sugarcane machine of 1st_modification ₆₀

6.7 Orientation of gear for 1st_modification ₆₀

6.8 CAD Isometric view of sugarcane machine for 2nd_{modification 63}

6.9 Orientation of gear for 2nd_modification ₆₃

6.10 Shaft A 67

6.11 Shaft B 68

6.12 Shaft C 69

6.13 Shaft D 70

6.14 Material properties table for AISI 1010 in solidworks analysis 71 6.15 Solidworks analysis on shaft A at 7mm diameter 72 6.16 Solidworks analysis on shaft B at 11mm diameter 73 6.17 Solidworks analysis on shaft D at 19mm diameter 74 6.18 Solidworks analysis on shaft F at 32mm diameter 75

6.19 Optimization on shaft A at 8mm diameter 76

6.20 Optimization on shaft A at 10mm diameter 77

6.21 Optimization on shaft B at 14mm diameter 78

6.22 Optimization on shaft D at 25mm diameter 79

6.23 Optimization on shaft F at 41mm diameter 80

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LIST OF SYMBOLS

m = module of gear

dp = diameter pitch

�′� = velocity factor

f = face width

�ͭ = force transmitted

� = lewis factor

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LIST OF ABBREVIATIONS

CAD = Computer-Aided Design

CAE = Computation-Aided Engineering

FEA = Finite Element Analysis

PDS = Product Design Specification

EDS = Engineering Design Specification

MEM = Mineral Extraneous Matter

BOM = Bill of Material

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LIST OF APPENDIX

APPENDIX A 106

A. Existing Sugar Cane Machine 107

B. Lost material by wear of journal of sugar cane machine 107

C. Sugarcane Compression Test 107

D. Existing Manual Sugarcane Machine 108

E. Sugarcane and Sugarcane Juice 108

F. Crushing Sugarcane by Assistance of Cow 108

G. Mechanical Sugarcane Machine from Wood 109

H. Big Size’s Mechanical Sugarcane Machine 109

APPENDIX B 110

A. Gantt Chart for PSM I 111

B. Gantt Chart for PSM II 112

APPENDIX C 113

A. Layout Drafting of Assembly Drawing 114

B. Layout Drafting of Body Left 115

C. Layout Drafting of Body Right 116

D. Layout Drafting of Top Handle 117

E. Layout Drafting of Supporting Shaft 118

F. Layout Drafting of Gear Cover 2 119

G. Layout Drafting of Gear Cover 1 120

H. Layout Drafting of Juice Collector 121

I. Layout Drafting of Steering 122

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NO. TITLE PAGE

K. Layout Drafting of Bearing 10mm 124

L. Layout Drafting of Drive Shaft 125

M. Layout Drafting of 200-40mm Gear 126

N. Layout Drafting of Shaft 14mm 127

O. Layout Drafting of Bearing 14mm 128

P. Layout Drafting of 40-200mm Gear 129

Q. Layout Drafting of Shaft 25mm 130

R. Layout Drafting of Bearing 25mm 131

S. Layout Drafting of 200mm Gear 132

T. Layout Drafting of Upper Roller 133

U. Layout Drafting of 65mm Gear 134

V. Layout Drafting of Bearing 41mm 135

W. Layout Drafting of Lower Roller 136

APPENDIX D 137

A. Ball Bearing Table 138

B. AISI Material Properties Table 139

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CHAPTER I

INTRODUCTION

This chapter will roughly introduce the background of the sugar cane and also the usage of the existing sugar cane crusher. Besides, some ideas regarding the demands of the white sugar that produced by extracting the sugar cane will also been touched under this chapter. Last but not least, the usage and the importance of the mechanical power’s sugar cane crusher will also being introduce in this chapter.

1.1 Background Study

Sugar cane is well known with its purpose especially to produce the white sugar in our daily life. They are native to warm temperate to tropical regions of Asia and they have stout, jointed, fibrous stalks that are rich in sugar and measure 2 to 6 meters tall. All sugar cane are interbreeds species, and the major commercial cultivars are complex hybrids. By determining the taxonomic interpretation, sugar cane, is any of 6 to 37 species of tall perennial grasses of the genus, Saccharum, which is the family of Poaceae, Tribe Andoprogoneae.

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the end of 2009, and to range around 18 cents in 2010, compared with 11.81 cents per lb touched on the last trading day of 2008, according to median forecasts. [22]

Furthermore, besides producing white sugar, sugar cane is also famous with its delicious juices. This juice is usually extracted by using a semi-automated sugar cane crusher that we usually can see in the market. The machine is built up by some gears and bearing which connected to an operating motor. There will be a space that designed for us to insert the sugar cane for extracting the juice. For some advanced machines, the clinker of the sugar cane will be directed and stored in a separated part after extracting the juice.

On the other hands, there is another type of sugar cane extractor that might operate by only using mechanical power. The whole structures and also the parts involved to built up this type of machine are almost same with the semi-automated type, just this type of extractor are no longer connected to an operating motor, but to a handle that operating by human energy. However, due to the lower efficiency of this type of extractor, it is not suitable for commercial used in the market.

1.2 Problem Statement

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1.3 Objectives

To design an efficient machine/mechanism that able to extract sugar cane juice by using only mechanical power.

1.4 Scope

The machine designed will be based on the studies conducted by referring to the existing sugar cane machine, whether it is pure mechanical power or semi-automated machine. And here are some scopes of the studies:

i. Conduct literature review.

ii. Design few conceptual designs that fulfill the engineering design specification.

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CHAPTER II

LITERATURE REVIEW

Under the chapter of literature review, it focuses on the studies that related to the project. All the theories, observations, surveys, recitations and also understanding of the documentations regarding the project are needed. These are for ensuring the project can be carried out in a better and smoother condition. Other information such as materials used, mechanism involved and software used for the purpose of analysis also will be included in this chapter.

2.1 History and Background of Sugar Cane

Sugar cane originated in New Guinea where it has been known since about 6000 BC. From about 1000 BC its cultivation gradually spread along human migration routes to Southeast Asia and India and east into the Pacific. It is thought to have hybridised with wild sugar canes of India and China, to produce the 'thin' canes. It spread westwards to the Mediterranean between 600-1400 AD. [1]

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[image:24.595.129.515.197.523.2]

Around 1420 the Portuguese introduced sugar cane into Madeira, from where it soon reached the Canary Islands, the Azores, and West Africa. Columbus transported sugar cane from the Canary Islands to what is now the Dominican Republic in 1493. The crop was taken to Central and South America from the 1520s onwards, and later to the British and French West Indies [1].

Figure 2.1: Sugar Cane [15]

2.2 Sugar in South Asia

Sugar cane has a very long history of cultivation in the Indian sub-continent. The earliest reference to it is in the Atharva Veda (1500-800 BC) where it is called Ikshu and mentioned as an offering in sacrificial rites. The Atharva Veda uses it as a symbol of sweet attractiveness.